Troubleshooting

Error code system

Order number Date Valid from serial number T-code
258944-040 2008-08-25 6053221- 838, 839, 840

7.4 Error code system

See the tables below for an explanation of the error code system.

Structure Description
G.ANN Example 3.510
G (3) Group. States which system is affected by the error.
A (5) Error category. Describes the type of fault that occurred and
what happened.
NN (10) Error code

Group Description
1 Do not use
2 Transistor regulator and logic card
3 The drive system
4 The hydraulic system
5 Do not use
6 Do not use
7 Do not use
8 Option

Error cate- Description

gory
0 Use caution. Mainly an information code, which indicates that
certain of the truck's functions are reduced or do not work.
1-2 Lifting errors. Raising and lowering of the forks is impaired or
not working and the truck's speed is reduced to safety speed.
3 Do not use.
4 Critical error. The main contactor opens. The truck stops.
5 Critical error. The main contactor opens. The truck stops.

Code Description
00-09 Diverse error codes.
10-19 CAN related error codes.
20-39 Error codes regarding specific units.
40-59 Error codes for short-ciruited outputs.
60-79 Error codes for open electrical circuits.
80-99 Faulty signals from sensors.

© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 7– 5

Troubleshooting
Error codes
T-code Valid from serial number Date Order number
838, 839, 840 6053221- 2008-08-25 258944-040

7.5 Error codes

NOTE that certain error codes are stored in the programme and disap-
pear from the display while other error codes remain on the display and
require that the truck is first stopped and then restarted for the error
code to disappear.

Code Event Possible cause

Measure
Transistor regulator and logic card
2.001 The transistor regulator stops all functions. Emergency switch pressed.
Check:
• that the emergency switch is unaf-
fected
• cable 24.
• Fuse [F51]
2.002 No event. The truck can be driven. Certain parameter values may be out-
side the predefined values. Reset the
parameters to standard values.
Check the parameter settings.
2.003 No event. The truck can be driven. Time for service.
Check the service meter (timer S). This
may not have been reset after the last
service.
2.004 No event. The truck can be driven. The values in the transistor regulator's
backup file is different from the values
in the handle's logic card with regards
to parameters, timers and/or machine
number.
Check via TruckCom where the correct
data is.
2.101 Safety speed, raising and lowering the The truck type has not been indicated.
forks not working.
State the truck type by adjusting factory
parameter 1001 (Truck type).
2.102 Safety speed, raising and lowering the The stated truck type does not support
forks not working. the analogue raising and lowering func-
tions.
Check the factory parameter settings
1001 (Truck type) and 1023 (Hydraulic
function control).

7– 6 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

 Troubleshooting
Error codes
Order number Date Valid from serial number T-code
258944-040 2008-08-25 6053221- 838, 839, 840

Code Event Possible cause

Measure
2.511 The main contactor opens. CAN communication error.
Check:
• connections and wiring harness
• cables 119 and 120
• logic card in the handle.
2.514 The main contactor opens. CAN communication error.
Check:
• connections and wiring harness
• cables 119 and 120.
• logic card in the handle.
2.520 The main contactor opens. Fault in the software for the control
handle or microprocessors.
Download new software.
2.521 The main contactor opens. The safety reversing function is faulty.
Mechanical fault of fault with the hall
sensor that controls the safety revers-
ing function.
Check via TruckCom that the hall sen-
sor works.
2.522 The main contactor opens. Faulty power supply to the hall sensor.
Check via TruckCom that the hall sen-
sors work.
2.523 The main contactor opens. The main contactor is not activated.
• Check that the main contactor
works.
• Open the main contactor.
Drive system
3.001 Driving is prevented until the speed con- • The speed control is not in neutral
trol is in neutral. when starting.
• Faulty hall sensor.
Check:
• speed controller's function
• via TruckCom that the hall sensors
work.

© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 7– 7

Troubleshooting
Error codes
T-code Valid from serial number Date Order number
838, 839, 840 6053221- 2008-08-25 258944-040

Code Event Possible cause

Measure
3.002 The transistor regulator reduces the maxi- The transistor regulator's temperature
mum current to 50 %. exceeds +85°C. The driving may be
too intensive.
• Drive the truck less intensively.
• Check for dirt around the transistor
regulator. Too much dirt means that
the transistor regulator does not cool
down properly.
3.003 The transistor regulator reduces the maxi- The motor's temperature exceeds
mum current to 50 %. +150°C. The driving may be too inten-
sive.
• Drive the truck less intensively.
• Check for dirt around the motor. Too
much dirt means that the motor does
not cool down properly.
3.040 No event. The truck can be driven. Faulty energy saving function in the
holding position.
• Internal fault in the transistor regulator.
• Restart the truck.
• If the error persists, change the tran-
sistor regulator.
3.080 The transistor regulator reduces the maxi- The temperature sensor for the transistor
mum current to 50 %. regulator shows abnormal values.
• Internal fault in the transistor regulator.
• Restart the truck.
• If the error persists, change the tran-
sistor regulator.
3.081 The transistor regulator reduces the maxi- The temperature sensor for the motor
mum current to 50 %. shows abnormal values. The sensor
may be faulty.
Check cables (63/64) to the tempera-
ture sensor in the motor.
3.101 Safety speed, raising and lowering the The transistor regulator is using prede-
forks not working. fined current gain.
• Internal fault in the transistor regulator.
• Restart the truck.
• If the error persists, change the tran-
sistor regulator.

7– 8 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

 Troubleshooting
Error codes
Order number Date Valid from serial number T-code
258944-040 2008-08-25 6053221- 838, 839, 840

Code Event Possible cause

Measure
3.120 Safety speed, raising and lowering the Faulty control total for parameters in
forks not working. the transistor regulator.
• Internal fault in the transistor regulator.
• Restart the truck.
• Reprogramme the truck.
• If the error persists, change the tran-
sistor regulator.
3.121 Safety speed, raising and lowering the The transistor regulator cannot use the
forks not working. internal memory.
• Internal fault in the transistor regulator.
• Restart the truck.
• Reprogramme the truck.
• If the error persists, change the tran-
sistor regulator.
3.140 The horn does not work. The safety The horn output has short-circuited.
speed.
Check:
• connections and wiring harness
• cable 50
• the horn.
3.501 The main contactor opens. Faulty transistor regulator.
Check:
• the transistor regulator
• factory parameter 1001 (Truck type).
If the error persists, change the transis-
tor regulator.
3.502 The main contactor opens. The control handle's logic card cannot
download parameters to the transistor
regulator.
• Restart the truck.
• Change logic card in the handle.
• If the error persists, change the tran-
sistor regulator.

© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 7– 9

 Troubleshooting
Error codes
T-code Valid from serial number Date Order number
838, 839, 840 6053221- 2008-08-25 258944-040

Code Event Possible cause

Measure
3.510 The main contactor opens. CAN communication problem with the
transistor regulator when starting.
Check:
• connections and wiring harness
• cables 119 and 120
• logic card in the handle and possibly
change the card.
If the error persists, change the transis-
tor regulator.
3.511 The main contactor opens. The handle's logic card does not see
CAN data from the transistor regulator.
Check:
• connections and wiring harness
• cables 119 and 120
• logic card in the handle and possibly
change the card.
If the error persists, change the transis-
tor regulator.
3.512 The transistor regulator stops all functions. The transistor regulator does not see
CAN data from the control handle's
logic card.
Check:
• connections and wiring harness
• cables 119 and 120
• logic card in the handle and possibly
change the card.
If the error persists, change the transis-
tor regulator.
3.514 The main contactor opens. The logic card in the control handle
cannot send CAN data to the transistor
regulator.
Check:
• connections and wiring harness
• cables 119 and 120
• logic card in the handle and possibly
change the card.
If the error persists, change the transis-
tor regulator.

7 – 10 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

 Troubleshooting
Error codes
Order number Date Valid from serial number T-code
258944-040 2008-08-25 6053221- 838, 839, 840

Code Event Possible cause

Measure
3.515 The transistor regulator stops all functions. The transistor regulator discovers CAN
communication error.
Check:
• connections and wiring harness
• cables 119 and 120
• logic card in the handle and possibly
change the card.
If the error persists, change the transis-
tor regulator.
3.520 The transistor regulator stops all functions. The transistor regulator discovers
short-circuit in the output step.
Check:
• motor cables
• motor
• the transistor regulator.
3.521 The transistor regulator stops all functions. The transistor regulator discovers low
motor voltage.
Check:
• motor cables
• motor
• the transistor regulator.
3.522 The transistor regulator stops all functions. The transistor regulator discovers high
motor voltage.
Check:
• motor cables
• motor
• the transistor regulator.
3.523 The transistor regulator stops all functions. The transistor regulator discovers inter-
nal problems with its own software or
hardware.
Internal fault in the transistor regulator.
Reprogramme the truck both in the
handle and the transistor regulator.
3.524 The transistor regulator stops all functions. The transistor regulator discovers inter-
nal problems with its own software or
hardware.
Internal fault in the transistor regulator.
Reprogramme the truck both in the
handle and the transistor regulator.

© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 7 – 11

 Troubleshooting
Error codes
T-code Valid from serial number Date Order number
838, 839, 840 6053221- 2008-08-25 258944-040

Code Event Possible cause

Measure
3.525 The transistor regulator stops all functions. The transistor regulator discovers that
the motor phase is always 0 (zero).
Check:
• motor cables
• motor
• the transistor regulator.
3.526 The transistor regulator stops all functions. The transistor regulator's voltage feed
is wrong.
Internal fault in the transistor regulator.
Change transistor regulator.
3.527 The transistor regulator stops all functions. Faulty transistor regulator software.
Internal fault in the transistor regulator.
Check that the last software for the
transistor regulator exists.
3.528 The transistor regulator stops all functions. Internal problem for the transistor regu-
lator's microprocessor.
• Internal fault in the transistor regulator.
Check that the last software for the
transistor regulator exists.
• If the error persists, change the tran-
sistor regulator.
3.529 The transistor regulator stops all functions. The transistor regulator discovers an
internal problem.
• Internal fault in the transistor regula-
tor. Check the software.
• If the error persists, change the tran-
sistor regulator.
3.530 The transistor regulator stops all functions. The transistor regulator discovers an
internal problem.
• Internal fault in the transistor regula-
tor. Check the software.
• If the error persists, change the tran-
sistor regulator.
3.531 The transistor regulator stops all functions. The transistor regulator discovers an
internal problem.
• Internal fault in the transistor regula-
tor. Check the software.
• If the error persists, change the tran-
sistor regulator.

7 – 12 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

 Troubleshooting
Error codes
Order number Date Valid from serial number T-code
258944-040 2008-08-25 6053221- 838, 839, 840

Code Event Possible cause

Measure
3.532 The transistor regulator stops all functions. The transistor regulator has an internal
problem in the AD transformer.
• Internal fault in the transistor regula-
tor.
• Change transistor regulator.
3.533 The transistor regulator stops all functions. The charging voltage for the transistor
regulator's capacitor shows abnormal
values.
Check:
• connections and wiring harness
• cable 20
• the transistor regulator.
• pump contactor
If the error persists, change the transis-
tor regulator.
3.534 The transistor regulator stops all functions. The transistor regulator discovers a
problem with the speed sensor. The
jump in frequency is too great.
Check:
• connections and wiring harness
• the speed sensor and possibly
change it.
3.535 The transistor regulator stops all functions. Faulty control total for parameters in
the transistor regulator.
Download new programme in the han-
dle and transistor regulator.
3.536 The transistor regulator stops all functions. The transistor regulator's current sen-
sor is outside valid intervals.
Internal fault in the transistor regulator.
Change transistor regulator.
3.537 The transistor regulator stops all functions. Multiple direction commands from the
handle.
Internal fault in the handle.
3.538 The main contactor opens. Unknown fault in the transistor regula-
tor.
• Internal fault in the transistor regula-
tor. Reprogramme the transistor reg-
ulator.
• If the error persists, change the tran-
sistor regulator.

© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 7 – 13

 Troubleshooting
Error codes
T-code Valid from serial number Date Order number
838, 839, 840 6053221- 2008-08-25 258944-040

Code Event Possible cause

Measure
3.539 The transistor regulator stops all functions. The transistor regulator discovers that
the battery voltage value lies o outside
24 V ±20%.
Check:
• the cables between the battery and
transistor regulator.
• the battery.
3.540 The transistor regulator stops all functions. The transistor regulator's output to the
main contactor has short-circuited.
Check:
• connections and wiring harness
• the main contactor.
3.541 The transistor regulator stops all functions. The transistor regulator's output to the
parking brake has short-circuited.
Check:
• connections and wiring harness
• the parking brake.
3.542 The transistor regulator stops all functions. One of the transistor regulator's circuits
to the main contactor, parking brake or
lowering valve has shortcircuited
at+24 V when starting.
Check
• connections and wiring harness
• main contactor
• parking brake
• lowering valve.
3.560 The transistor regulator stops all functions. The transistor regulator's output to the
main contactor is open.
Check:
• connections and wiring harness
• the main contactor.
3.561 The transistor regulator stops all functions. The circuit between the transistor regu-
lator and the coil in the main contactor
is open.
Check:
• connections and wiring harness
• the main contactor.

7 – 14 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

 Troubleshooting
Error codes
Order number Date Valid from serial number T-code
258944-040 2008-08-25 6053221- 838, 839, 840

Code Event Possible cause

Measure
3.562 The transistor regulator stops all functions The transistor regulator's output to the
parking brake is open.
Check:
• connections and wiring harness
• parking brake.
3.563 The transistor regulator stops all functions. The transistor regulator's coil circuit to
the parking brake is open.
Check:
• connections and wiring harness
• parking brake.
3.580 The transistor regulator stops all functions. Main contactor closed.
Check:
• connections and wiring harness
• the main contactor.
3.581 The transistor regulator stops all functions. Main contactor closed.
Check:
• connections and wiring harness
• the main contactor.
• main fuse [F1]
3.582 The transistor regulator stops all functions. The transistor regulator's output for
power supply has the wrong voltage
level.
Check:
• connections and wiring harness
• the main contactor
• lowering valve
• brake
• pump contactor.
Internal fault in the transistor regulator.
Change transistor regulator.
3.583 The transistor regulator stops all functions. The transistor regulator's internal
power supply does not increase.
Internal fault in the transistor regulator.
Change transistor regulator.

© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 7 – 15

 Troubleshooting
Error codes
T-code Valid from serial number Date Order number
838, 839, 840 6053221- 2008-08-25 258944-040

Code Event Possible cause

Measure
Hydraulic system
4.001 Lifting is prevented until the analogue con- The analogue control for lifting and low-
trol of lifting and lowering is back in the ering is not in the neutral setting when
neutral setting. starting. (Applies to SWE trucks).
Speed control not affected when start-
ing the truck.
Check:
• cable in the handle
• potentiometer. For fault, change po-
tentiometer.
4.101 Safety speed, raising and lowering the Analogue control signals for lifting and
forks not working. lowering shows abnormal values.
Speed control not affected when start-
ing the truck.
Check:
• cable in the handle
• potentiometer. If broken, change po-
tentiometer.
4.102 Safety speed, raising and lowering the The handle type does not correspond
forks not working. with the adjustment for factory parameter
1023 “Control for hydraulic function”.
Check the adjustment for factory
parameter 1023 and compare with the
truck's handle.
4.125 Safety speed, raising and lowering the The pump motor's current feedback is
forks not working. always zero when the pump motor is in
operation.
The current sensor in the transistor
regulator is faulty. Change transistor
regulator.
4.126 Safety speed, raising and lowering the The pump motor's current feedback is
forks not working. too high when starting and in holding
position.
The current sensor in the transistor
regulator is faulty. Change transistor
regulator.
4.521 The main contactor opens. The pump motor's voltage is too low.
Check:
• the cable between the transistor reg-
ulator and pump motor.
• the pump motor.

7 – 16 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

 Troubleshooting
Error codes
Order number Date Valid from serial number T-code
258944-040 2008-08-25 6053221- 838, 839, 840

Code Event Possible cause

Measure
4.522 The main contactor opens. The pump motor's voltage is too low.
Check:
• the cable between the transistor reg-
ulator and pump motor.
• the pump motor.
4.540 The transistor regulator stops all functions. • The transistor regulator's output to
the lowering valve has short-
circuited.
• Internal short-circuit in the transistor
regulator.
• Check connections and wiring har-
ness
• Loosen the connection to the lower-
ing valve and try to restart.
• If the error persists, change the low-
ering valve or change the transistor
regulator.
4.541 The transistor regulator stops all functions. The transistor regulator's output to the
lowering valve has short-circuited to B-.
Check connections and wiring harness
4.560 The transistor regulator stops all functions. The transistor regulator's output to the
lowering valve is open.
Check:
• connections and wiring harness
• the lowering valve's coil.
Option
8.001 Safety speed, raising and lowering the The collision sensor has registered col-
forks not working. lision levels that are above the stated
limits.
• Drive carefully.
• Check the limits for registering colli-
sions (service parameters 105 and
106).
8.002 Safety speed, raising and lowering the The truck has deliberately been put in
forks not working. an unusable state by TLS.
Reset the truck to normal operation.

© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 7 – 17

 Troubleshooting
Error codes
T-code Valid from serial number Date Order number
838, 839, 840 6053221- 2008-08-25 258944-040

Code Event Possible cause

Measure
8.003 No event. The truck can be driven. Argument warning from the Spider
expansion unit.
Check the settings for selected param-
eters.
8.010 No event. The truck can be driven. CAN communication problem with the
battery charger when starting.
Check connections and wiring harness
8.011 No event. The truck can be driven. The handle's logic card does not see
CAN data from the battery charger.
Check connections and wiring harness
8.014 No event. The truck can be driven. The logic card in the control handle
cannot send CAN data to the battery
charger.
Check connections and wiring harness
8.020 No event. The truck can be driven. The battery charger is not connected to
the battery.
Check connections and wiring harness
8.021 No event. The truck can be driven. The battery charger has discovered
low battery voltage.
Check the battery's status
8.022 No event. The truck can be driven. The battery charger has discovered
high battery voltage.
Check the battery's status
8.023 No event. The truck can be driven. The battery charger has discovered
low charging temperature.
Charge the battery at normal tempera-
ture.
8.024 No event. The truck can be driven. The battery charger has discovered
high charging temperature.
Check:
• dirt in the battery charger. Clean if
needed.
• that the fan works.
8.027 No event. The truck can be driven. Serious fault in the battery charger.
Change battery charger.
8.028 No event. The truck can be driven. The battery cahrger has exceeded the
time limit for charging.
Check the battery.

7 – 18 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

 Troubleshooting
Error codes
Order number Date Valid from serial number T-code
258944-040 2008-08-25 6053221- 838, 839, 840

Code Event Possible cause

Measure
8.029 No event. The truck can be driven. The battery charger charges more than
maximum capacity.
Check:
• battery
• service parameter 110.
8.030 No event. The truck can be driven. There is a battery charger in the truck,
but has not been activated via factory
parameter 1101.
Check factory parameter 1101.
8.031 No event. The truck can be driven. Faulty parameter adjustment for the
battery charger.
Restart the truck. Check that the truck
and battery charger have the right soft-
ware.
8.110 Safety speed, raising and lowering the CAN communication problem with Spi-
forks not working. der expansion unit 1 when starting.
Check connections and wiring harness
8.111 Safety speed, raising and lowering the CAN communication problem with Spi-
forks not working. der expansion unit 1.
Check connections and wiring harness
8.114 Safety speed, raising and lowering the CAN communication problem with Spi-
forks not working. der expansion unit 2 when starting.
Check connections and wiring harness
8.115 Safety speed, raising and lowering the CAN communication problem with Spi-
forks not working. der expansion unit 2.
Check connections and wiring harness
8.123 Safety speed, raising and lowering the Spider expansion unit 1 programme
forks not working. warning.
Check parameter selections.
8.124 Safety speed, raising and lowering the Spider expansion unit 2 programme
forks not working. warning.
Check parameter selections.

© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 7 – 19